Patent GB-1494606-A (GB)
Title: Process for the production of foams
IPC: C08J9/08
Filed: 1976-06-03
Abstract: 1494606 Polyurethane foams BAYER AG 3 June 1976 [4 June 1975] 22950/76 Heading C3R A process for the production of a polyurethane foam comprises reacting, in a closed mould, a mixture comprising an organic polyisocyanate, which is preferably liquid at room temperature, an organic compound which splits off carbon dioxide under the influence of a basic catalyst and a compound which contains NCO-reactive hydrogen atoms and has a M.wt. of from 62- 10,000 and has mixed with it and/or chemically built into it a basic compound, which acts as a catalyst for the decomposition of the said organic compound, the reaction being carried out in the presence of water and/or an organic blowing agent. The organic compound which splits off CO 2  is preferably an anhydride of the formula R 1 -[-(O) n COOCOOR 2 ] m , wherein m= 1 or 2, n = 0 or 1 when m = 1, and n = 0 when m = 2; R 1  represents an m-valent C 1 -C 18  aliphatic hydrocarbon group which may be olefinically unsaturated, a C 4 -C 10  cycloaliphatic hydrocarbon group, a C 6 -C 10  aromatic hydrocarbon group or a C 7 -C 10  araliphatic hydrocarbon group; and R 2  is a monovalent R 1  radical. Suitable anhydrides are pyrocarbonic acid di-(C 1 -C 4 ) alkyl esters, acetic or propionic acidcarbonic acid-ethyl ester anhydride, sebacic- or adipic-acid-bis(carbonic acid methyl ester)- anhydride and crotonic acid-carbonic acidmethyl ester-anhydride. The addition of the organic compound which splits off CO 2  to the reaction mixture increases the difference between the fibre time and cream time of the foaming process resulting in foams with a more homogeneous vertical density distribution. The resulting foams preferably have a compact surface skin. The basic catalysts may be alkali metal hydroxides or alcoholates but are preferably tertiary amines. Suitable compounds containing NCO reactive hydrogen atoms with chemically built in basic centres are amino polyethers which may be obtained by alkoxylation of primary and/or secondary monoamines or polyamines containing at least 2 NH-bonds. The polyisocyanate may be any aliphatic, cycloaliphatic, araliphatic, aromatic or heterocyclic polyisocyanate, and numerous examples are listed. Preferred polyisocyanates are diphenylmethane diisocyanates containing carbodiimide and/or uretone imine groups, or polyisocyanates obtained by reacting 4,41-diisocyanatodiphenylmethane with low M.wt. diols or triols. Preferred compounds containing NCO-reactive hydrogen atoms are polyhydroxyl compounds, e.g. polyesters, polyethers, polythioethers, polyacetals, polycarbonates, polyamides, polyester-amides and polyethers modified by vinyl polymers. Additional catalysts which may be present are organic tin compounds. The reaction mixture may contain conventional additives, e.g. foam stabilizers, cell regulators, reaction retarders, stabilizers, flame-retardants, plasticizers, dyes, fillers, fungicides and bactericides. The process is preferably carried out by the one-shot process. In Example 1 a hard polyurethane integral foam is prepared by mixing component (A) comprising a polyol mixture of (1) a polyether which is an ethylene oxide/trimethylolpropane adduct; (2) a polyester prepared from adipic acid, phthalic acid anhydride, oleic acid and trimethylol-propane, and (3) a polyether which is an ethylene oxide/ ethylamine adduct; a polysiloxane-polyalkylene oxide block copolymer as foam stabilizer, pentamethyldiethylene triamine as catalyst, an amidamine oleic acid salt of 3-dimethyl-aminopropylamine-(1) and oleic acid as internal mould release agent, aqueous H 3 PO 4  as reaction retarder and monofluoro-trichloromethane as blowing agent; with component (B) comprising pyrocarbonic acid diethyl ester and a polyisocyanate obtained by phosgenation of aniline/ HCHO condensates followed by reaction with a mixture of tri- and tetra-propylene glycols; in a 2-component dosing and mixing apparatus and introducing the foamable reaction mixture into a closed mould.